Flail rotor head attachment

ABSTRACT

A flail rotor head attachment for use with any type harvesting machine having crop residue processing elements and including an input opening for receiving crop residue. The attachment includes a frame structure for operatively coupling the attachment to the harvesting machine, a flail rotor and an auger each mounted on the frame structure and a drive mechanism for rotating the flail rotor and the auger. The flail rotor includes a plurality of cutting elements for picking up and chopping crop residue from a field. The auger includes at least two flightings positioned in opposite directions for funneling crop residue towards the opening of the harvesting machine. Another embodiment includes a rake positioned between the flail rotor and the auger, the rake and the flail rotor rotating in the same direction and the auger rotating in an opposite direction.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. patent applicationSer. No. 13/404,959, filed Feb. 24, 2014, the entire contents of all ofwhich are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates generally to head attachments forharvesting machines and, more particularly, to a flail rotor headattachment which is especially adapted for use in conjunction with aforage harvester.

The automation of crop harvesting is an integral aspect of modernagriculture. Devices to aid and improve the harvesting process arewidely sought after to reduce costs and improve efficiency. Automationhas increased the speed at which many crops are harvested and it hasreduced the necessity of manual labor. However, the automation ofharvesting still remains relatively expensive in instances where the useof multiple machines is required due to the costs of paying machineoperators, fuel, maintenance and the purchase of the machinesthemselves.

Once a crop has been harvested from a field, varying amounts of cropresidue (e.g. stalks, leaves, roots, chaff, tare, stubble, straw, cobs,pods, hulls, fibers, silage, fodder or other plant matter) remain in theharvested fields. Crop residue has a number of different uses, forexample, it is sometimes further processed in a variety of ways for useas bio-fuel, animal feed or other bi-products. Collecting crop residuefrom harvested fields oftentimes involves the use of several differenttypes of machines. For example, once a corn crop has been harvested,standing corn stubble or already combined corn stalks remain in thefield. This corn stubble or stalks is typically harvested for use asanimal feed. Normally a series of machines or operations are required tocollect the corn residue and convert it into animal feed. First, thecorn stubble or stalks need to be cut, chopped and windrowed in a firstoperation. Windrowing is a row of cut crop residue such as a small graincrop or hay which is organized and collected in a row on the ground andallowed to dry before being baled, combined or rolled as necessary.Typically, a flail windrower machine is used to accomplish this task. Aflail windrower will cut, shred and windrow the remaining corn stalks ina single pass and will build neat, uniform windrows on the ground readyfor baling or stacking. Depending upon the type of crop residue, thevolume of such residue from time to time may necessitate the use of arake for combining two or more windrows together, creating piles of cropresidue large enough to be processed such as by a forage harvester.

Once the corn residue is windrowed, the windrowed stalks are typicallybaled in a second operation through the use of a baler machine. Thebaler will parcel the crop residue into bales for pickup at a latertime. Alternatively, if a baler is not used, a forage harvester may beused to pick up the windrowed crop residue and load the same into avehicle for transport. The bailed or otherwise gathered corn residue isthen transported to a feed yard in a transportation operation where thebales or collected crop residue are then further ground and mixed withother feed or supplements in a further operation for use as animal feed.These multiple operations are time consuming; they can take several daysor weeks to accomplish; and the use of multiple machines is expensivewhen you consider the cost of each machine, the fuel consumptionrequired, and the manpower necessary to accomplish these multiple tasks.

In present day harvesting operations, there is therefore a need forimproving the efficiency of gathering and collecting crop residue andfor reducing the number of machines and/or operations necessary toaccomplish the task. Streamlining the overall operation and reducing theoverall costs involved is desirous.

BACKGROUND OF THE INVENTION

The present invention relates generally to head attachments forharvesting machines and, more particularly, to a flail rotor headattachment which is especially adapted for use in conjunction with aforage harvester.

The automation of crop harvesting is an integral aspect of modernagriculture. Devices to aid and improve the harvesting process arewidely sought after to reduce costs and improve efficiency. Automationhas increased the speed at which many crops are harvested and it hasreduced the necessity of manual labor. However, the automation ofharvesting still remains relatively expensive in instances where the useof multiple machines is required due to the costs of paying machineoperators, fuel, maintenance and the purchase of the machinesthemselves.

Once a crop has been harvested from a field, varying amounts of cropresidue (e.g. stalks, leaves, roots, chaff, tare, stubble, straw, cobs,pods, hulls, fibers, silage, fodder or other plant matter) remain in theharvested fields. Crop residue has a number of different uses, forexample, it is sometimes further processed in a variety of ways for useas bio-fuel, animal feed or other bi-products. Collecting crop residuefrom harvested fields oftentimes involves the use of several differenttypes of machines. For example, once a corn crop has been harvested,standing corn stubble or already combined corn stalks remain in thefield. This corn stubble or stalks is typically harvested for use asanimal feed. Normally a series of machines or operations are required tocollect the corn residue and convert it into animal feed. First, thecorn stubble or stalks need to be cut, chopped and windrowed in a firstoperation. Windrowing is a row of cut crop residue such as a small graincrop or hay which is organized and collected in a row on the ground andallowed to dry before being baled, combined or rolled as necessary.Typically, a flail windrower machine is used to accomplish this task. Aflail windrower will cut, shred and windrow the remaining corn stalks ina single pass and will build neat, uniform windrows on the ground readyfor baling or stacking. Depending upon the type of crop residue, thevolume of such residue from time to time may necessitate the use of arake for combining two or more windrows together, creating piles of cropresidue large enough to be processed such as by a forage harvester.

Once the corn residue is windrowed, the windrowed stalks are typicallybaled in a second operation through the use of a baler machine. Thebaler will parcel the crop residue into bales for pickup at a latertime. Alternatively, if a baler is not used, a forage harvester may beused to pick up the windrowed crop residue and load the same into avehicle for transport. The bailed or otherwise gathered corn residue isthen transported to a feed yard in a transportation operation where thebales or collected crop residue are then further ground and mixed withother feed or supplements in a further operation for use as animal feed.These multiple operations are time consuming; they can take several daysor weeks to accomplish; and the use of multiple machines is expensivewhen you consider the cost of each machine, the fuel consumptionrequired, and the manpower necessary to accomplish these multiple tasks.

In present day harvesting operations, there is therefore a need forimproving the efficiency of gathering and collecting crop residue andfor reducing the number of machines and/or operations necessary toaccomplish the task. Streamlining the overall operation and reducing theoverall costs involved is desirous.

SUMMARY OF THE INVENTION

The present invention teaches the construction and operation of severalembodiments of a flail rotor head attachment adaptable for use with aforage harvester and other machines in gathering, collecting, cuttingand chopping crop residue such as already combined corn stalks in asingle pass for use as animal feed or other bi-products. The presentapparatus combines multiple operations associated with gathering andusing crop residue, which streamlined operation is more efficient,greatly improves the method of harvesting crop residue, eliminatesmultiple passes over the same harvested field using a multitude ofdifferent types of farm equipment, and it greatly improvesprofitability. By mounting the present flail rotor head attachment onthe front of a forage or silage harvester, the operator is able toextract corn stalks or stubble or other crop residue from a row, cut andchop the foliage into a ready-to-feed form, and then place the choppedcrop residue into a vehicle such as a truck or wagon for transportationto a feed yard or other location. This process is completed with onemachine and one operator thereby replacing the need for the use ofmultiple machines and multiple operators as presently accomplished. Thepresent apparatus and process eliminates the need for use of a flailwindrower for windrowing the crop residue, and it likewise eliminatesthe need for raking, baling or rolling the crop residue prior totransportation to its end destination.

In accordance with the teachings of one embodiment of the presentinvention, a flail rotor head attachment for gathering standing ordowned crop residue is disclosed wherein the apparatus includes ahousing and associated frame structure operably coupled to the frontportion of a forage harvester or other harvesting type machine, thehousing including a flail rotor and an auger. The flail rotor includes aplurality of cutting elements for cutting and/or chopping crop residueenroute to the forage harvester. In this regard, the flail rotor ispositioned and located so as to pick up the crop residue directly off ofthe ground and then feed such crop residue into an associated auger forfunneling the residue through the input opening associated with theforage harvester. The auger feeds the crop residue from each oppositeend portion towards the center for discharge into the inlet opening ofthe forage harvester. A driveline with an associated drive sprocketpowers the flail rotor and auger through connection to the forageharvester. In this regard, the present apparatus includes a driveassembly which is powered by the driveline for moving the flail rotorand auger in the same direction. The drive assembly may include aplurality of pulleys, drives, tensioners, and other mechanisms forconnecting the flail rotor and the auger to the driveline. The drivelineis conventionally coupled to a gear box or other power means associatedwith the forage harvester or an adapter as will be hereinafter furtherexplained.

In another aspect of the present invention, the flail rotor headattachment is provided with a rake mechanism for receiving crop residuefrom the flail rotor and thereafter passing such crop residue onto theauger. In this particular embodiment, the rake mechanism is locatedbetween the flail rotor and the auger and includes a shaft with aplurality of pick-up teeth associated therewith. The rake shaft islikewise coupled to the drive assembly for powering the rake mechanismthrough the driveline associated with the present apparatus. Dependingupon the type of crop residue being collected, the rake mechanism willimprove the pick-up and funneling of the crop residue to the auger.Where the rake mechanism is utilized, the flail rotor and rake willrotate in the same direction while the auger will rotate in the oppositedirection.

The flail rotor, auger and rake mechanisms are all supported on a framestructure associated with the overall housing. This frame structurelikewise includes an attachment mechanism for coupling the overall headattachment to a forage harvester or other crop harvesting machine. Inaddition, it is recognized and anticipated that the flail rotor, rakemechanism and auger may include a plurality of such mechanisms coupledtogether for unit movement. The housing may likewise include a hood forproviding access to the internal structure of the present headattachment. Still further, the various embodiments of the present flailrotor head attachment can be utilized and coupled to any work machine inaccordance with the teachings of the present invention.

It is therefore an object of the present invention to improve theoverall efficiency of removing crop residue from a harvested field byeliminating the multiple passes which are currently necessary toaccomplish this task.

These and other objects and advantages of the present flail rotor headassembly will become apparent to those skilled in the art afterconsidering the following detailed description of several illustrativeembodiments of the present invention in connection with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present invention, reference may bemade to the accompanying drawings.

FIG. 1 is a perspective view of one embodiment of the present flailrotor head assembly constructed in accordance with the teachings of thepresent invention shown attached to a forage harvester.

FIG. 2 is a cross-sectional view of the present flail rotor headattachment of FIG. 1 taken through the exit opening of the housing andthe input opening of an adapter associated with a forage harvester.

FIG. 3A is a partial perspective view of one embodiment of a flail rotorassociated with the flail rotor head attachment of FIG. 1.

FIG. 3B is a partial perspective view of one embodiment of an augerassociated with the flail rotor head attachment of FIG. 1.

FIG. 4 is a partial perspective view showing a conventional Kuma adapterand the exit opening of the flail rotor head attachment of FIG. 1.

FIG. 5 is a perspective view of the flail rotor head attachment of FIG.1 attached to a forage harvester and showing the drive assemblyassociated therewith.

FIG. 6 is a bottom plan form view of the flail rotor head attachment ofFIG. 1.

FIG. 7 is a front elevational view of the flail rotor head attachment ofFIG. 1 attached to a forage harvester.

FIG. 8 is a cross-sectional view of another embodiment of the presentflail rotor head attachment taken through the exit opening of thehousing and the input opening of a forage harvester constructed inaccordance with the teachings of the present invention.

FIG. 9 is a partial perspective view of the flail rotor head attachmentof FIG. 8 attached to a forage harvester and showing the drive assemblyassociated therewith.

FIG. 10 is a side view of the second side of the flail rotor headattachment of FIG. 8.

It should be understood that the present drawings are not necessarily toscale and that the embodiments disclosed herein are sometimesillustrated by fragmentary views. In certain instances, details whichare not necessary for an understanding of the present invention or whichrender other details difficult to perceive may have been omitted. Itshould also be understood that the invention is not necessarily limitedto the particular embodiments illustrated herein. Like numbers utilizedthroughout the various figures designate like or similar parts orstruct.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings more particularly by reference numbers,wherein like numerals refer to like parts, FIGS. 1-7 identify oneembodiment of a flail rotor head attachment 10 for cutting andcollecting crop residue from the ground. The flail rotor head attachment10 may be operably attached to a forage harvester such as the forageharvester 20, or to any other similar type of machine which furtherprocesses crop residue. In this embodiment, the forage harvester 20operates in a traditional manner by cutting and chopping the cropresidue and the present flail rotor head attachment 10 operates to moreeffectively and efficiently gather, collect and cut crop residue priorto entry into the forage harvester in a single pass thereby eliminatingmultiple passes over the same harvested field with different types offarm equipment to accomplish the same task. Once the crop residue hasbeen processed by both the present head attachment 10 and the forageharvester 20, the forage harvester 20 feeds the crop residue into achute 30 for depositing the crop residue into a vehicle such as thevehicle 40 illustrated in FIG. 1 for transporting the processed cropresidue to its end destination.

As illustrated in FIGS. 2, 3A, 3B, 4 and 5, the flail rotor headattachment 10 includes a housing 50 and associated frame structure foroperably connecting or coupling the attachment 10 to the front portionof a forage harvester 20. The housing 50 may further include a hood 60which may be removably attached or otherwise opened and/or removed foraccess to the flail rotor 70 and the auger 80. The housing 50 may beoperably attached to the frame structure by any suitable attachmentmeans.

As illustrated in FIGS. 2, 3A, 3B, 4 and 5, the flail rotor headattachment 10 includes a housing 50 and associated frame structure foroperably connecting or coupling the attachment 10 to the front portionof a forage harvester 20. The housing 50 may further include a hood 60which may be removably attached or otherwise opened and/or removed foraccess to the flail rotor 70 and the auger 80. The housing 50 may beoperably attached to the frame structure by any suitable attachmentmeans.

In one embodiment, the flail rotor head attachment 10 includes a flailrotor 70 and an auger 80. The attachment 10 may include one or moreflail rotors 70 operatively coupled together to function as a singleunit, and it may include one or more augers 80 similarly operativelycoupled together to function as a single unit, depending on the desiredlength of the overall head attachment 10 as will be hereinafter furtherexplained.

The flail rotor 70 as best illustrated in FIGS. 2-4 and 6-8 ispositioned in front of auger 80 and includes a plurality of cuttingelements 90 for cutting and/or chopping crop residue as it picks up suchresidue from the ground and funnels it to the auger 80 and to the forageharvester 20. The cutting elements 90 may be removable from the flailrotor 70 for facilitating sharpening and/or replacement and, in theembodiment illustrated in FIGS. 2-4, are operably secured to the flailrotor 70 such that they extend outward in their operative position whenthe flail rotor 70 is in motion. In this regard, each cutting element 90is freely attached to a bracket or clamp member 92 by means of acarriage clasp or ring type member 94 which allows the cutting element90 to freely move from a position wherein the element 90 lies adjacentto or abutting the flail rotor 70 as shown in FIG. 3A to an operativeextended position as shown in FIGS. 2 and 4. The rotational movement orcentrifugal force generated by rotation of the flail rotor 70 keeps thecutting elements 90 extended to both cut and collect the crop residue asthe attachment 10 moves through a harvested field. The bracket member 92may include a stop mechanism or other structure for preventing thecutting elements 90 from over extending. In an alternative embodiment,the cutting elements 90 may be attached to the flail rotor 70 so as topermanently extend in an operative position. The flail rotor 70functions to cut, chop and remove crop residue including harvested cornstalks directly from the ground. The flail rotor 70 is also positionedand located in the housing 50 and relative to the auger 80 asillustrated in FIG. 2 so as to feed the crop residue into auger 80 forfunneling the crop residue out of the housing exit opening 56 (FIG. 4)and into the input opening 100 of a conventional Kuma adapter 175.

It is also recognized that the flail rotor 70 can include a single rotorextending the full width of the head attachment 10 such as the widthillustrated in FIG. 1, or the flail rotor 70 can include a plurality ofrotors 70 coupled in operative alignment with each other so as to spanthe entire width of the head attachment 10 and such that the driveassemblies 160 associated with each opposite end of the attachment 10drive the entire plurality of flail rotors 70. In this regard, as bestillustrated in FIG. 6, a pair of flail rotors 70 are illustrated thereinconnected in operative alignment with each other and coupled at eachopposite end to a respective drive assembly 160 for powering the same.It is recognized and anticipated that any plurality of flail rotors,including more than two rotors 70, can be operatively connected inalignment with each other to both accommodate the overall width of thehead attachment 10 and to facilitate installation and maintenancethereof.

The flail rotor head attachment 10 likewise includes an auger 80 as bestillustrated in FIGS. 2-4 and 6. The auger 80 includes a pair offlightings 130A and 130B as best illustrated in FIGS. 3B and 6, eachflighting 130 being oriented in a manner so as to funnel the cropresidue coming into contact with the flightings 130A and 130B from theflail rotor 70 towards the center of the head attachment 10 and, moreparticularly, towards the housing exit opening 56 for feeding such cropresidue through the exit opening 56 and into the input opening 100associated with the Kuma adapter 175 (FIG. 4). As illustrated in FIGS.3B and 6, the auger 80 in this particular embodiment includes twoseparate augers coupled in operative alignment with each other, oneauger 80 including the fighting 130A and the other auger 80 includingthe flighting 130B. As best illustrated in FIG. 3B, auger 80 includingthe flighting 130A includes a shaft portion 110 and the auger 80including flighting 130B includes a shaft portion 120, the shaftportions 110 and 120 being operatively connected together at one endportion thereof as illustrated in FIG. 6 and having their opposite endportions connected to the respective drive assemblies 160. The auger 80is positioned and located aft of the flail rotor 70 and rotates in thesame direction as compared to the flail rotor 70 such that the cropresidue received from the flail rotor 70 is continuously moved andfunneled rearwardly through the auger 80 and through the housing exitopening 56 as illustrated in FIG. 2. The housing 50 may include a shieldmember 82 positioned and located underneath the auger 80 and adjacent tothe flail rotor 70 for facilitating the funneling of the crop residuefrom the flail rotor 70 to the auger 80. The shield 82 also helps toprevent crop residue from falling to the bottom of the housing 50 andbecoming unavailable for funneling to the forage harvester 20.

As with the flail rotor 70, any plurality of augers 80 can beoperatively connected in alignment with each other so long as theflightings 130A and 130B are properly oriented with respect to theplurality of augers so that the crop residue is again funneled to themiddle of the housing and to the exit opening 56. It is likewiserecognized and anticipated that a single auger 80 can be utilized solong as the fighting associated with each opposite end portion of asingle auger is again configured differently so as to be comparable tothe flightings 130A and 130B such that the crop residue will be funneledto the center portion of the housing 50.

As best illustrated in FIGS. 5 and 6, a driveline 140 is associated withthe rear portion of the head attachment 10 for providing power to thedrive assemblies 160 located at each opposite end portion of the flailrotor 70 and auger 80. The driveline 140 and the drive assemblies 160form the drive mechanism of the attachment 10. The driveline 140includes a drive sprocket 150 located at each opposite end portionthereof for powering the auger 80 and it likewise includes a sprocket orpulley 155 located at each opposite end portion thereof for powering theflail rotor 70 as will be hereinafter further explained. The entiredrive assembly 160 located at each opposite end of the head attachment10 is powered by the driveline 140 which is conventionally coupled to agear box 170 or other power means associated with either the adapter 175or the forage harvester 20.

The drive assemblies 160 may include a plurality of pulleys, sprockets,drives, tensioners and other mechanisms for connecting the flail rotor70 and the auger 80 to the driveline 140. In this regard, as bestillustrated in FIG. 6, the driveline 140 is split at the center thereofand includes a pair of connecting members 142 for coupling to a gear box170 or other power means associated with either an adapter or the forageharvester 20. In the particular embodiment illustrated in FIGS. 4 and 5,a conventional Kuma adapter 175 is utilized between the forage harvester20 and the present head attachment 10 for coupling the head attachment10 to the harvester 20. The Kuma adapter is well-known in the industryand is used to attach any combine-type head to a forage harvester. TheKuma adapter 175 includes a drive shaft 177 (FIG. 4) which is attachableat each opposite end portion to the coupling members 142 associated withdriveline 140. A gear box 170 (FIGS. 4 and 5) is associated with theadapter 175 and powers the drive shaft 177. In turn, the driveline ofthe forage harvester 20 is connected to the gear box 170 and powers thesame. Here again, depending upon the type of adapter used, the driveline140 can be connected to the power means of the forage harvester 20through the adapter by any suitable means. Still further, in certainsituations, it is also recognized and anticipated that the driveline 140can be coupled directly to the power means associated with the forageharvester by any suitable coupling means.

In the embodiment illustrated in FIGS. 5 and 6, the drive assemblies 160each further include an auger drive sprocket 210 which is operativelycoupled to the auger 80 and is further operatively coupled to the drivesprocket 150 via a chain, belt or other drive means 220 for facilitatingrotation thereof as best illustrated in FIG. 5. In similar fashion, theflail rotor 70 includes a flail drive pulley or sprocket 180 which isoperatively coupled to the flail rotor 70 and is further operativelycoupled to the drive pulley or sprocket 155 via a belt, chain or otherdrive means 190 for facilitating rotation thereof as best illustrated inFIG. 5. A tensioning mechanism 200 is positioned and located adjacent tothe flail drive pulley or sprocket 180 and engages the belt or otherdrive means 190 for ensuring that the drive means 190 remains tight whenthe flail rotor 70 is in operation. A similar tensioning sprocket 215 ispositioned and located to engage the chain or other drive means 220 forensuring that the drive means 220 remains tight when the auger 80 is inoperation. It is recognized and anticipated that other drive assemblyarrangements may likewise be utilized at each opposite end of the headattachment 10 for turning the flail rotor 70 and the auger 80 in thesame direction. It is also recognized and anticipated that only onedrive assembly 160 located at only one of the opposite ends of theattachment 10 may be utilized to rotate the flail rotor 70 and the auger80.

In operation, when the driveline 140 is engaged and rotating, the drivesprocket 150 in conjunction with the auger sprocket 210 and itsassociated drive means 220 turn the auger 80 in one direction. In asimilar arrangement, the drive pulley or sprocket 155 in conjunctionwith the flail drive pulley or sprocket 180 and its associated drivemeans 190 turn the flail rotor 70 in one direction. As best illustratedin FIG. 2, the flail rotor 70 cuts and picks up crop material from theground and the cutting elements 90 move the crop residue to the auger 80so that the auger 80 can then funnel the crop residue through thehousing exit opening 56 and into the adapter opening 100 for feeding thecrop residue into the forage harvester 20. The housing 50 associatedwith the present head attachment 10 is configured so as to facilitatethe funneling of the crop residue from the flail rotor 70 to the auger80.

As best illustrated in FIG. 4, the Kuma adapter 175 likewise includes aconveying means in the form of rotating blades 179 for feeding the cropresidue through the Kuma adapter 175 and into the forage harvester. Oncethe crop residue is inside the forage harvester, the harvester 20 willfurther cut, chop and process the crop residue into a ready-to-feed formfor transfer to a vehicle such as the vehicle 40 (FIG. 1) fortransportation to a feed yard or other location. The additional cuttingand chopping accomplished by the flail rotor 70 and its ability togather and collect crop residue directly from the ground enables theforage harvester to further process such residue into a ready-to-feedform. This process is completed with one machine and one operator in asingle pass thereby replacing the need for using multiple machines andmultiple operators such as use of a flail windrower for first windrowingthe crop residue, and it likewise eliminates the need for raking, balingor rolling the crop residue for further processing at another location.

In yet another embodiment illustrated in FIG. 8, the present flail rotorhead attachment 15 may include a flail rotor 70, an auger 80 and a rake230 positioned therebetween. The rake 230 includes a plurality of tines250 for further engaging the crop residue and facilitating the funnelingof the crop residue from the flail rotor 70 to the auger 80. Dependingupon the type of crop residue being collected, the tines 250 of the rake230 help to further break up the crop residue and move such residue tothe auger 80 thereby preventing any clogging or jamming of the cropresidue enroute to the auger 80. The tines 250 may be removable forfacilitating adjustment and/or replacement and they can be secured tothe rake 230 in any conventional manner. In this embodiment, theattachment 15 is coupled directly to the front portion of the forageharvester 20.

Like the flail rotor 70 and auger 80, depending upon the overall widthof the present head attachment 15, any plurality of rakes 230 may beoperatively connected in alignment to further facilitate movement of thecrop residue within the housing 50. Like flail rotor 70 and auger 80,the rake 230 is connected to at least one drive assembly 160′ (FIG. 9)in a conventional manner such as by including additional drive sprocketsor pulleys at at least one opposite end portion of the driveline 140′for operative connection to a rake drive sprocket or pulley associatedwith at least one opposite end of the rake 230. Rotation of thedriveline 140′ will likewise rotate the rake 230 in the same directionas flail rotor 70 when the associated sprockets and other drivecomponents are operatively coupled to each other through the use ofchains, belts, gear boxes or other drive mechanisms. The auger 80 willrotate in the opposite direction relative to flail rotor 70 and rake230. Since the rake 230 turns in the same direction as the flail rotor70, the drive pulley or sprocket associated with the rake 230 could becoupled to the pulleys or sprockets 155 and 180 associated with flailrotor 70 for movement in the same direction as the flail rotor 70 and inthe opposite direction as the auger 80.

FIG. 9 illustrates one embodiment of a drive assembly 160′ for drivingthe flail rotor 70, the rake 230 and the auger 80. A driveline 140′ isassociated with the rear portion of the head attachment 15 for providingpower to the drive assembly 160′ located on one end portion of theattachment. The driveline 140′ powers and rotates the drive sprocket150′ and also powers a main gear box 260 located at the proximate endportion thereof. The drive assembly 160′ may include a plurality ofpulleys, sprockets, drives, tensioners and other mechanisms forconnecting the flail rotor 70, the rake 230 and the auger 80 to thedriveline 140′. In this regard, the driveline 140′ includes a couplingmember (not shown) for coupling the power means of the forage harvester20 to the driveline 140′ of the head attachment 15. In this particularembodiment, the driveline 140′ can directly couple the head attachment15 to the power means associated with the forage harvester 20 by anysuitable coupling means. Still further, in certain situations, it isalso recognized that an adapter may be utilized between the forageharvester 20 and the present head attachment 15 for coupling the headattachment 15 to the harvester 20.

The main gear box 260 is operatively coupled to a double sprocket 270via a chain, belt or other drive means for facilitating the rotation ofauger drive sprocket 210′ as illustrated in FIG. 9. The auger drivesprocket 210′ is further coupled to the auger 80 for facilitatingrotation of the auger 80 in an opposite direction as compared to theflail rotor 70 and the rake 230. The gear box 260 is a reverse gear boxwhich facilitates rotation of the double sprocket 270 in the oppositedirection. The second sprocket (not shown) associated with sprocket 270turns the auger drive sprocket 210′ via a chain, belt or other drivemeans 212.

The drive sprocket 150′ is further coupled to a driveline doublesprocket 280 via a chain, belt or other drive means 192 for facilitatingrotation thereof. Similarly, the double sprocket 280 is operativelycoupled to a flail drive sprocket 180′ via a chain, belt or other drivemeans 194 for facilitating rotation thereof. The flail drive sprocket180′ is further coupled to the flail rotor 70 for facilitating rotationof the flail rotor 70 in the same direction as the rake 230. In similarfashion, a rake gear box 290 located behind gear box 260 is coupled tothe main gear box 260 for facilitating the rotation of a rake sprocket300. The rake sprocket 300 is operatively coupled to a rake drivesprocket 310 via a chain, belt or other drive means 320 for facilitatingthe rotation thereof. The rake drive sprocket 310 is further coupled tothe rake 230 for facilitating rotation of the rake 230 in the samedirection as the flail rotor 70. A tensioning mechanism 202 ispositioned and located adjacent to the flail drive sprocket 180′ andengages the belt or other drive means 194 for ensuring that the drivemeans 194 remain tight when the flail rotor 70 is in operation. Thistensioning mechanism 202 is similar to tensioning mechanism 200. Anadditional tensioning mechanism 204 is positioned and located adjacentto the double sprocket 280 and engages the belt or other drive means 192for ensuring that the drive means 192 remains tight when the drivelinedouble sprocket 280 is in operation. The housing 50′ associated with theattachment 15 may likewise include a shield member 85 positioned andlocated as illustrated in FIG. 8 for likewise facilitating the funnelingof the crop residue from the rake 230 to the auger 80.

As best illustrated in FIGS. 9 and 10, the double sprocket 280 isoperatively coupled to the driveline 330 for powering a correspondingsprocket 350 located on the opposite end portion of the attachment 15relative to the double sprocket 280. The sprocket 350 is operativelycoupled to a flail drive sprocket 180′ via a chain, belt or other drivemeans 196 for facilitating rotation thereof at the opposite end portionof the attachment. A tensioning mechanism 206 is positioned and locatedadjacent to the flail drive sprocket 180′ and engages the belt or otherdrive means 196 for ensuring that the drive means 196 remains tight whenthe flail drive sprocket 180′ is in operation similar to tensioningmechanism 202. This arrangement provides additional drive power to theflail rotor 70. In this particular embodiment, the auger 80 and the rake230 are powered from one side only of the attachment 15 via the driveassembly 160′.

It is likewise recognized and anticipated that other drive mechanismscould be utilized in association with drive assembly 160′ for turningthe rake 230 in the same direction as the flail rotor 70 and for turningthe auger 80 in the opposite direction. In all other respects, thepresent head attachment 15 including the flail rotor 70, the auger 80,the housing 50, and its associated other components function and operatein a manner substantially similar to the operation of head attachment10. Like attachment 10, attachment 15 can likewise be coupled to anadapter under certain conditions.

Either embodiment of the present invention, namely, head attachment 10or head attachment 15, can be mounted to the front of a forage harvester20 or other harvesting type machine in a conventional manner such asthrough the use of an adapter such as adapter 175, or they can beattached directly to a forage harvester 20, or by other conventionalmeans, for extracting crop residue from a harvested field as explainedabove. Both embodiments of the present invention eliminate the need formultiple passes over the harvested field and both embodiments cut, chopand collect the crop residue for further processing by the forageharvester 20.

The housing 50 may also include a plurality of hollow tool bars 58 whichfunction as a stabilizing means for the housing 50. It is recognized andanticipated that other means may likewise be used to stabilize thehousing 50, if necessary. The housing 50 may further include a pluralityof vents 360 (FIG. 9) which functions to regulate the release of heat,dust and exhaust from the attachments 10 and 15. It is recognized andanticipated that other means may likewise be used to vent theattachments 10 and 15, if necessary. It is also recognized that thefront portion of the attachments 10 and 15 may likewise include anyplurality of wheels (not shown) for facilitating movement of theattachments 10 and 15 through a harvested field.

Thus, there has been shown and described several embodiments of a novelhead attachment to a forage harvester. As is evident from the foregoingdescription, certain aspects of the present invention are not limited bythe particular details of the examples illustrated herein, and it istherefore contemplated that other modifications and applications, orequivalents thereof, will occur to those skilled in the art. The terms“having” and “including” and similar terms as used in the foregoingspecification are used in the sense of “optional” or “may include” andnot as “required”. Many changes, modifications, variations and otheruses and applications of the present invention will, however, becomeapparent to those skilled in the art after considering thisspecification and the accompanying drawings. All such changes,modifications, variations and other uses and applications which do notdepart from the spirit and scope of the invention are deemed to becovered by the invention which is limited only by the claims whichfollow.

1. A flail rotor head attachment for attachment to a harvesting machinehaving crop residue processing elements, a power source and including aninput opening for receiving crop residue into a harvesting machine, theattachment comprising: a frame structure for operatively coupling theattachment to the front portion of a harvesting machine; a housinghaving an exit opening for positioning in alignment with the inputopening of a harvesting machine; a flail rotor mounted on said framestructure, said flail rotor including a plurality of cutting elementsfor picking up and chopping crop residue from a field; an auger mountedon the frame structure for receiving crop residue from the flail rotor,the auger having at least two flightings positioned in oppositedirections for funneling crop residue towards the exit opening of thehousing for delivery to the input opening of a harvesting machine; arake positioned between the flail rotor and the auger, said rakeincluding a plurality of tines for further engaging the crop residue andfor facilitating the funneling of the crop residue from the flail rotorto the auger; and a drive mechanism coupled to said flail rotor, saidauger and said rake for rotating said flail rotor and said rake in thesame direction relative to each other and for rotating said auger in anopposite direction relative to said flail rotor and said rake.
 2. Theflail rotor head attachment of claim 1 wherein the housing includes ahood for providing access to the flail rotor, auger and rake.
 3. Theflail rotor head attachment of claim 1 wherein the plurality of flailrotor cutting elements are removable.
 4. The flail rotor head attachmentof claim 1 wherein said frame structure includes coupling means foroperatively attaching the attachment to the front portion of aharvesting machine.
 5. The flail rotor head attachment of claim 1wherein said flail rotor includes a plurality of rotors coupled inoperative alignment with each other, said drive mechanism driving saidplurality of flail rotors.
 6. The flail rotor head attachment of claim 1wherein said auger includes a plurality of augers coupled in operativealignment with each other, said drive mechanism driving said pluralityof augers.
 7. The flail rotor head attachment of claim 1 wherein saidauger includes at least two augers coupled in operative alignment witheach other, one auger including one fighting and the other augerincluding the other fighting.
 8. The flail rotor head attachment ofclaim 1 wherein said rake includes a plurality of rakes coupled inoperative alignment with each other, said drive mechanism driving saidplurality of rakes.
 9. The flail rotor head attachment of claim 1wherein said plurality of tines are removable.
 10. The flail rotor headattachment of claim 1 wherein said drive mechanism includes a drivelineand at least one drive assembly associated with said attachment fordriving said flail rotor, said auger and said rake, said driveline beingcoupled to a power source associated with a harvesting machine.
 11. Theflail rotor head attachment of claim 1 including an adapter coupledbetween the attachment and a harvesting machine, said adapter includingmeans for feeding the crop residue from the exit opening of theattachment to the input opening of a harvesting machine.
 12. The flailrotor head attachment of claim 1 wherein said housing includes aseparate shield member positioned under said auger and adjacent to saidflail rotor for facilitating the funneling of the crop residue from therake to the auger.
 13. The flail rotor head attachment of claim 10wherein said driveline is connected to a drive sprocket, said drivesprocket turning a flail rotor drive sprocket coupled to said flailrotor.
 14. The flail rotor head attachment of claim 13 wherein said atleast one drive assembly includes other drive elements for connectingsaid flail rotor drive sprocket to said drive sprocket.
 15. The flailrotor head attachment of claim 14 wherein said other drive elementsinclude at least one of a chain and a pulley.
 16. The flail rotor headattachment of claim 14 including at least one tensioning element. 17.The flail rotor head attachment of claim 10 wherein said driveline isattached to a drive sprocket, said drive sprocket turning an auger drivesprocket coupled to said auger.
 18. The flail rotor head attachment ofclaim 17 wherein said at least one drive assembly includes other driveelements for connecting said auger drive sprocket to said drivesprocket.
 19. The flail rotor head attachment of claim 18 wherein saidother drive elements include at least one of a chain and a pulley. 20.The flail rotor head attachment of claim 18 including at least onetensioning element.
 21. The flail rotor head attachment of claim 10wherein said driveline is connected to a drive sprocket, said drivesprocket turning a rake drive sprocket coupled to said rake.
 22. Theflail rotor head attachment of claim 21 wherein said at least one driveassembly includes other drive elements for connecting said rake drivesprocket to said drive sprocket.
 23. The flail rotor head attachment ofclaim 1 wherein each of said cutting elements is attached to a separaterespective bracket member, each cutting element being separatelyremovable from a respective bracket member without removing said bracketmember from said flail rotor, each bracket member allowing eachrespective cutting element to move freely between a first positionwherein the cutting element lies adjacent to the flail rotor and asecond position wherein the cutting element extends outwardly in anoperative position.
 24. The flail rotor head attachment of claim 23including a stop mechanism associated with each bracket member forpreventing the cutting elements from over-extending.